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Crushing plants - what are they and how do I set one up?

Yellow excavator feeding a yellow barford 750j jaw crusher feeding into a yellow and gray barford sr124 onsite crushing and screening large piles of concrete and rocks

What is a crushing plant?

Are you a construction business owner or contractor looking to crush concrete, rock or asphalt? If so, you may be wondering what a crushing plant is. A crushing plant is a row of machines that break down large chunks of material into smaller pieces in the quickest most efficient way.

Crushing plants are an important part of the mining, quarrying, and recycling industries. They can even be set up as stationary plants or mobile ones, depending on your business's needs. In this blog post, we will find out the different kinds of crusher plants in more detail.

yellow ARK 704 jaw crusher on a concrete plinth feeding into a yellow and gray ARK 5030 scalping screen that is also on a concrete plinth. The crusher and screener are working though piles of concrete.

Crushing plant setup

A crushing plant setup is a series of machines that are designed to take large pieces of concrete, asphalt or rock and break them into smaller pieces. The crushed material can then be used for construction, landscaping, and other purposes. 

Stage 1 of the crushing plant - Excavator

There are many different kinds of machines used in a crushing plant. At the beginning of the plant is the excavator. This scoops up large blocks of concrete, rock or asphalt from your stockpile and places them into the first crusher. There are typically two types of crusher machines used in a plant setup: a jaw crusher or an impact crusher. There are lots of different sized and shaped excavators and buckets available, so you will always be able to find one for your specific job. You can check out all the different types of excavators here.

yellow john deere excavator feeding ashalt into a yellow and gray ARK 704 jaw crushing machine
Excavators feed the crusher with material at the start of the crushing plant

Stage 2 of the crushing plant - Crusher

A jaw crusher is great for breaking down very large pieces of rock into smaller more manageable sizes. These smaller chunks can then be fed into an impact crusher. These work by metal rotors smashing the material against the inside an impact chamber. Creating a much smaller material that is a similar shape and size. If you are thinking of running a jaw and impact crusher in the sequence you should read this blog on primary crushers this has all the information you need to know. And, if you want to know more about the differences between jaw and impact crushers, just click the link! 

You can also run a crushing plant without an impact crusher, especially if your budget is tighter. 

yellow barford 750j jaw crusher feeding material into a barford sr124 3-way scalping screener on a dusty construction site
Jaw crusher feeding into a screener

Stage 3 of the crushing plant - Screener

If you're setting up a crushing plant, a screener can be an essential piece of equipment. It can help you to get the most out of your crushers by sorting the materials they make into stockpiles of the same size. You can then use these directly on your projects for landscaping or to make pavement fill or sell them for a profit!

When choosing a screener for your crushing plant, it's important to select one that is durable and easy to maintain. You'll also want to think about the type of material you'll be working with and the product you want to make. With so many options on the market, it's important to work with a reputable supplier who can help you choose the right screener for your needs. Machinery Partner is always here to help you choose the best screener for your business with a full range of scalping screens and trommels available directly from the manufacturer.

yellow and gray ark 5030 3-way scalping screen sitting on a concrete mound and screening concrete into  different sized products and materials. the screener is being fed by an ark 704 jaw crusher
A screener in your crushing plant will help you make high spec materials

Should I use a mobile or stationary crushing plant setup?

When deciding between mobile and stationary crushing plants, you should think about the pros and cons of each setup.

Mobile crushing plants are easily transportable, cost-effective, and can be moved around quickly to different work sites. Mobile crushing plants require regular maintenance and may use more fuel, plus they can’t process as many materials at once. On the other hand, stationary crushers are usually located in one spot, so there’s no need to move them from job site to job site. This does however mean that you will lose the flexibility of being able to move it when needed and you will need to have a permanent location where the crusher and or screener will stay. 

The choice between a mobile or stationary crushing plant depends on your needs: mobile units are better for short-term projects that require frequent travel while stationary ones are recommended for more time-intensive jobs that remain in one spot.

gray and blue static omega jaw crusher inside a warehouse
Static jaw crushers are great if you have a permanent location to keep them

I just have a crusher at the moment - why should I upgrade and setup a full crushing plant for my business?

When it comes to crushers, bigger is better. Having just a crusher for your business can be fine for gravel, cement, and concrete but when it comes to more complex crushing materials, such as minerals, ore and metals, the jaw crusher isn't always enough. 

Setting up a crushing plant gives you the ability to process higher volumes of material in different sizes much faster than a jaw crusher alone would. If you're processing different kinds of materials or just need to process large amounts of material quickly, then setting up a crushing plant is essential. 

A crushing plant gives you access to larger crushers and screens so that you can process more material in fewer passes. You'll also be able to keep production running longer with smaller machines because there's less wear on them when compared with just using one crusher over extended periods. 

In short, if you need high-volume crushing capabilities and are looking to expand your business into more complex areas of crushing materials, then setting up a crusher plant is your best choice!  All in all, setting up a full crushing plant offers greater flexibility, better efficiency and improved productivity rather than relying on a single crusher alone.

Can I match any crusher with any screener?

Setting up a crushing plant involves careful consideration and selection of all its machines to make sure they match each. This is the only way you can make quality materials with minimal wear and tear on machinery. 

You should always think about the tones per hour (tph) each machine can handle. If your jaw crusher works at 200 tph, you can’t match it with an screener than can only handle 50 tph!

When you are setting up a crushing plant you also need to think about the feed heights of the machine's hoppers compared to the conveyor height of the machine in front of it. Take a look at this setup below. This is a jaw crusher feeding a screener. See how the conveyor of the jaw crusher nicely feeds into the screener?

Getting a bit complicated? Don’t worry - Machinery Partner are here to help. We have decades of experience when it comes to crushing and screening and can help you with all kinds of crushing plant setups and advice. Get in touch with a Machinery Partner expert today!

barford 750j jaw crusher feeding a supply of crushed rock into the hopper of a barford sr124screener which is making 3 different sized piles of rock
Matching conveyor to hopper height is important when setting up a crushing plant

Machinery Partner will find you the best crushing plant setup

Need crushers, screeners or excavators for your crushing plant setup? 

Machinery Partner has you covered! We have a large selection of crushers, screeners and excavators for sale at competitive prices. Our team of experts can help you navigate the range to find the best machinery for your specific crushing plant and material need.

Whether you're crushing stone, asphalt, or metal waste and debris, Machinery Partner can help you put together a set of crushers, screeners and excavators that will get the job done right. So if you want to get your crusher plant up and running quickly and efficiently, Machinery Partner is here to help. Call a Machinery Partner expert today!

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